Self cleaning sump cover

Abstract

A fluid flow system for a laundry appliance includes a blower that delivers process air along an airflow path having a heat exchanger. A drain channel receives condensate from the heat exchanger and fluid spray from a spray nozzle for directing lint particles to the drain channel and on to a sump for collecting fluid, including the condensate. A pump seat and a fluid outlet are integrally formed in a sump cover. A pump directs the fluid from the sump to the fluid outlet. A fluid level sensor detects at least minimum and maximum capacities of the fluid in the sump. When the fluid is below the minimum capacity, the pump defines an idle state. When the fluid reaches the minimum capacity, the pump defines an active state. When the fluid exceeds the maximum capacity, the pump directs the fluid to the fluid outlet.

What is claimed is: 
     
       1. A fluid flow system for a laundry appliance, the fluid flow system comprising:
 a blower that delivers process air along an airflow path; 
 a heat exchanger for dehumidifying the process air and removing condensate therefrom; 
 a drain channel that receives the condensate from the heat exchanger and fluid spray from a spray nozzle for directing lint particles to the drain channel; 
 a sump that collects fluid from the drain channel, wherein the fluid at least partially includes the condensate; 
 a sump cover that includes a pump seat and a fluid outlet that are integrally formed in the sump cover; 
 a pump that directs the fluid from the sump and to the fluid outlet; and 
 a fluid level sensor that detects at least a minimum capacity and a maximum capacity of the fluid in the sump, wherein:
 when the fluid is below the minimum capacity, the pump defines an idle state; 
 when the fluid reaches the minimum capacity, the pump defines an active state; and 
 when the fluid reaches the maximum capacity, the pump directs a flow of the fluid to the fluid outlet of the sump cover; 
 wherein the pump is selectively operable to direct the fluid from the sump and through the fluid outlet to a fluid diverter valve, wherein the fluid diverter valve selectively and alternatively directs the fluid to a removable bottle and the spray nozzle; and 
 wherein the fluid level sensor is coupled to a control that operates the pump, wherein the pump selectively operates according to an override that suspends operation of the fluid level sensor; wherein:
 the override activates the pump when a level of the fluid is below the minimum capacity at completion of a drying cycle; and 
 the pump is deactivated when the fluid in the sump reaches the maximum capacity and the fluid in the removable bottle reaches a full capacity. 
 
 
 
     
     
       2. The fluid flow system of  claim 1 , wherein the fluid level sensor includes a multi-component sensor that includes a lower sensor and an upper sensor, wherein:
 the lower sensor detects when the fluid in the sump reaches the minimum capacity; and 
 the upper sensor detects when the fluid in the fluid level sensor reaches the maximum capacity. 
 
     
     
       3. The fluid flow system of  claim 1 , further comprising:
 a lint filter that captures lint particles from the process air within an upstream surface of the lint filter, wherein the spray nozzle directs a spray of fluid from the sump to a surface of the lint filter to direct the lint particles from the upstream surface and toward the drain channel. 
 
     
     
       4. The fluid flow system of  claim 3 , wherein the pump is selectively operated to deliver fluid from the sump to the spray nozzle, via the fluid diverter valve, during performance of a spray sequence, wherein the fluid from the spray nozzles is directed into the drain channel and is recirculated back to the sump to define recirculated sump fluid, wherein the pump directs the recirculated sump fluid to the spray nozzles via the fluid diverter valve until completion of the spray sequence. 
     
     
       5. The fluid flow system of  claim 4 , wherein the recirculated sump fluid includes the condensate from the heat exchanger and lint particles from the upstream surface of the lint filter. 
     
     
       6. The fluid flow system of  claim 1 , wherein the sump cover includes an integral overflow port that is in communication with the removable bottle, wherein excess fluid from the removable bottle is directed into the sump via the overflow port. 
     
     
       7. The fluid flow system of  claim 1 , wherein the sump cover includes a perimeter seal that engages a perimeter wall of the sump. 
     
     
       8. The fluid flow system of  claim 7 , wherein the sump includes a cup portion that defines a fluid inlet and an impeller chamber, wherein the fluid inlet and the impeller chamber is in communication with the fluid outlet.